Building structure

ABSTRACT

A hexagonal building structure includes a series of vertical corner posts which are rigidly connected by a corresponding series of segment-shaped wall or bridge panels and corner brackets to form a rigid outer hexagonal frame. A rigid hexagonal inner frame is positioned concentrically within the outer frame, and a series of curved laminated wood beams extend radially outwardly from the inner frame over the outer frame and are secured by brackets to the inner and outer frames. A plurality of insulated plastic roof panels are mounted on the beams, and each roof panel has a spherical curvature conforming to the curvature of the beams. The outer edge of each roof panel curves in a vertical plane extending parallel to the corresponding wall panel, and a correspondingly curved gutter member extends along the outer edge of each roof panel. The inner frame defines a center opening which is covered by flat triangular transparent panels forming a hexagonal skylight, and rectangular wall panels are positioned between the corner posts under the bridge-like wall panels.

United States Patent 11 1 Cole [451 Apr. 30, 1974 1 BUILDING STRUCTURE [76] Inventor: John D. Cole, 3860 Honey Hill In,

Dayton, Ohio 45405 [22] Filed: Aug. 18, 1972 [21] Appl. No.: 281,844

Primary Examiner-John E. Murtagh Attorney, Agent, or FirmJacox & Meckstroth [57] ABSTRACT A hexagonal building structure includes a series of vertical comer posts which are rigidly connected by a corresponding series of segment-shaped wall or bridge panels and comer brackets to form a rigid outer hexagonal frame, A rigid hexagonal inner frame is positioned concentrically within the outer frame, and a series of curved laminated wood beams extend radially outwardly from the inner frame over the outer frame and are secured by brackets to the inner and outer frames. A plurality of insulated plastic roof panels are mounted on the beams, and each roof panel has a spherical curvature conforming to.the curvature of the beams. The outer edge of each roof panel curves in a vertical plane extending parallel to the corresponding wall panel, and a correspondingly curved gutter member extends along the outer edge of each roof panel. The inner framedefines a center opening which is covered by flat triangular transparent panels forming a hexagonal skylight, and rectangular wall panels are positioned between the comer posts under the bridgelike wall panels.

8 Claims, 14 Drawing Figures PATEMTEDAPR 30 I974 1180711 01 SHEET 2 OF 2 I BUILDING STRUCTURE BACKGROUND OF THE INVENTION In the construction of single family homes and multiple family dwelling units, there has been substantial effort made in creating or attempting to create building structures which are economical and practical in construction, but which have a more distinctive and attractive appearance than the conventional box-like structure having a truss constructed hip or gable roof. In the design of such a non-conventional structure, it is desirable to provide not only an attractive appearance and a practical, economical construction, but also a structure which can be quickly and conveniently erected at a building site and which has high strength for supporting substantial loads as occasionally result from accumulated 'snow. It is also desirable for the building structure to provide resistance to extreme changes in weather in addition to providing effective insulation to both high and low outside temperatures. It has further been found desirable for the interior of the building structure to provide the maximum usable floor space and for a feeling of spaciousness and openness by minimizing the number of walls which define 90 interior corners and by providing natural interiorlighting.

Among the many non-conventional building structures which have been either proposed or constructed, are the generally semispherical geodesic dome structures which are usually constructed of a combination of hexagonal and pentagonal preassembled wood panel units. There is also a semi-spherical dwelling structure which is manufactured by Tension Structures Inc. of Plymouth, Michigan, and sold under the trademark O- Dome. This structure consists of a series of generally triangular panels each consisting of a core of rigid polyurethane foam sandwiched between inner and outer layers or skins of fiberglass. It is also well-known to construct silos or grain bins with segmented domeshaped roofs or roofs formed by generally triangular overlapping'flat roof panels which are usually constructed of sheet metaL- After carefully analyzing the various building and roof structures referred to above, it is apparent that none of these structures provide all of the desirable features mentioned above.

SUMMARY OF THE INVENTION The present invention is directed to an improved building structurewhich is primarily adapted for single and multiple family dwellings or residences, but which may also be used for offices and other types of buildings. The building structure of the invention provides all of the desirable features mentioned above and is especially adapted for minimizing the time and labor required for erection at a building site in addition to providing an attractive and distinctive exterior and interior appearance and having a practical and economical construction.

In accordance with the illustrated construction, the building structure incorporates a series of six preassembled rectangular wall panels which are arranged in a hexagonal configuration. The rectangular wall panels are positioned between a corresponding series of vertical corner posts which are rigidly connected by a series of segment-shaped bridge-like wall panels to form an outer hexagonal frame. An inner hexagonal metal frame is positioned concentrically within the outer frame, and a series of arcuate or curved laminated wood beams rigidly connect the comers and sides of the inner frame to the corresponding corners and sides of the outer frame. A series of trapezoidal-shaped insulated roof panels are secured to the beams, and each of the roof panels is spherically curved at a radius which is substantially greater than the width of the building and which conforms to the curvature of the radially extending beams so that the entire roof structure has a uniform part-spherical curvature.

The inner frame defines an opening which is covered by a hexagonally shaped skylight structure, and the outer edge of each roof panel curves in a plane extending parallel to the corresponding side wall panel. Each of the roof panels consists of a core of rigid. polyurethane foam sandwiched between upper and lower fiberglass or thermoplastic sheets which are molded or vacuum formed to provide the spherical curvature. The upper sheet or skin of each roof panel includes outwardly projecting lips or flanges, and the flanges of adjacent panels overlap each other and the corresponding beam and receive a resilient gasket to form a watertight seal.

Other features and advantages of the building structure of the invention will be apparent from the follow ing description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a hexagonal building structure constructed in accordance with the invention;

FIG. 2 is a fragmentary vertical section of the structure shown in FIG. 1 when viewed generally on the line 2-2 of FIG. 3; 1 FIG. 3 is a fragmentary plan view of the building structure shownin FIG. 1 with the roof panels and skylight removed;

FIG. 4 is an enlarged fragmentary exploded section taken generally on the line 4-4 of FIG. 2;

FIG. 5 is an exploded perspective view of particular components'of the building structure shown in FIGS. 1-3;

FIG. 6 is an enlarged fragmentary section ofthe roof support structure as taken generally on theline 6-6 of FIG. 3;

FIG. 7 is another enlarged fragmentary section of the roof structure as taken generally on the line 7-7 of FIG. 3; r,

FIG. 8 is an enlarged fragmentary section taken generally on the line 8-8 of FIG. 2;

FIG. 9 is a further enlarged fragmentary section of the roof structure as taken generally on the line 9-9 of FIG. 3;

FIG. 10 is an enlarged fragmentary section of the roof support structure as taken generally on the line 10-10 of FIG. 2;

FIG. 11 is a fragmentary view of the center portion of the ceiling or roof structure as viewed along the line 11-11 of FIG. 2;

FIG. 12 is an enlarged perspective view of the skylight structure shown in FIGS. 1 and 2;

FIG. 13 is an exploded fragmentary section similar to FIG. 4 and showing a modification of the invention; and

DESCRIPTION OF THE PREFERRED EMBODIMENTS 2 is erected on a concrete slab or floor 15 which has a hexagonal configuration, but which may be constructed of wood, brick or other floor material and have a different configuration. Furthermore, while the building structure is illustrated in the form of a single level or one story structure, it will be apparent that the building may be a multiple level structure without departing from the scope of the invention.

- Mounted on the floor 15 or the underlying founda-v tion, are a series of six upright or vertical corner posts 16 which are located at the apexes of a hexagon and which have a generally triangular cross-sectional configuration as shown in FIG. 8. The lower ends of the corner post 16 are secured to the floor 16, and a pair of wood studs 17 (FIG. 8) are secured to the converging faces of each corner post 16. The upper ends of the corner posts 16 and studs 17 support the corresponding ends of a series of segment-shaped bridge-like wall pan-' els 18. Each of the panels 18 is formed by a correis rigidly secured to the corresponding end portions of the adjacent bridge panels 18 by a series of screws 24. Thusthe bridge panels 18, the corner posts 16, the

' studs 17 and the brackets 23 cooperate to form an outer hexagonal frame 25.

A series of preassembled rectangular insulated wall panels 28 are positioned between the comer posts 16 and studs 17, and each of the wall'panels 28 includes a peripherally extending wood frame 31 (FIGS. 6 and 8) which is dimensioned to interfit between each pair of opposing studs. 17 and under the corresponding bridge panel 18. As shown in FIGS. 1 and 5, the wall panels 28 may include a series of windows 32 and a door 34, or each wall panelmay have no windows or door or one or more windows of different sizes. As shown, in FIG. 6, the outer side of each wall panel 28 is covered by an exterior sheeting 37 which may consist of any exterior sheeting material such as rough sawn plywood. An interior sheeting 38 covers the inner side of each wall panel 28 and may consist of drywall, wood paneling or other interior sheeting material. The specific construction of each preassembled wall panel 28 forms no partof the present invention.

An inner hexagonal metal frame 45 (FIGS. and 7) is formed by welding sections of a heavy angle iron so that it includes a horizontal hexagonal flange 46 integrally connected to a vertical hexagonal flange 47. Each corner of the frame 45 includes a pair of parallel spaced brackets or plates 49 which are welded to the flanges 46 and 47, and two additional pairs of plates 49 are welded to each side of the frame 45 between the corners of the frame.

Referring to FIGS. 2-4, a series of arcuate beams 55 extend radially outwardly from the inner frame 45 over the outer frame 25 so that the outer end portion of each beam 55 projects in a cantilevered manner outwardly from the corresponding side wall 28 of the building structure. Each of the beams 55 has a uniform curvature formed at a radius R (FIG. 2) which is substantially greater than the distance D between an opposite pair of corner posts 16. For example, in one prototype construction of .the building, theradius R'was approximately 55 feet, and the distance D was approximately 33% feet.

Each of the beams 55 is formed by laminated wood strips 58 (FIGS. 6 and 7), and the inner end portion of each beam 55 is secured between a corresponding pair of bracket plates 49 by a set of bolts 59. The longer beams 55 which extendfrom the comers of the inner frame 45 are supported by the upper ends of the corresponding corner posts 16 (FIG. 10) of the outer frame 25. The set of shorter beams 55, which extendfrom each side of the inner frame 45, are supported within corresponding notches 62 (FIG. 5) formed within the upper curved surface of the corresponding bridge panel 18. An angular metal bracket 63 (FIG. 6) secures each beam 55 to the inner surface of the corresponding bridge panel 18 or cornerposts 16 of the outerhexagonal frame 25. i

A set of three trapezoid-shaped roof panels 66, 67 and 68 (FIGS. 1 and 5) extends from each side of the inner frame-45 to the corresponding side of the outer frame 25 and are mounted on the corresponding underlying arcuate beams SSLEach of the roof panels 66-68 includes a core 71 formed of a rigid plastic foam material such as expanded rigid polyurethane foam. The core 71 is sandwiched between an upper skin or sheet 72 and a lower skin or sheet 74 of a rigid plastics sheeting material such as layers or sheets of reinforced fiberglass or an ABS thermoplastics material. The foam core 71 and both of the upper and lower sheets 72 and 74 of each roof panel, have a uniform spherical curvature which conforms to the radius R of the beams 55. When the sheets 72 and 74 are formed of fiberglass, the fiberglass material is molded or laid-up in a mold having a spherical curvature. When the sheets 72 and 74 are formed from a thermoplastic sheet material, the sheets are heated and vacuum formed to the spherical curvature.

As shown in FIG. 4, the upper sheet 72 of each of the roof panels projects outwardly along the sidesof the panels to form a channel-shaped lip or flange 76. The

flanges 76 of each pair of adjacent roof panels are arranged in overlapping interfitting relation and are secured to the corresponding beam 55 by a series of Iongitudinally spaced screws 78 which extend through corresponding resilient sealing washers 79. A continuous strip 81 of a resilient gasket material is sandwiched between the overlying flanges 76 of the adjacent roof panels and forms a water-tight seal between the flanges.

Referring to FIG. 7, the inner edge of the upper sheet 72 of each of the roof panels 6668, is formed upwardly to form a flange 83 which assures that no water will seep inwardly around the inner edge of the roof panel. As shown in FIG. 1, the outer or lower edge of each of the spherically curved roof panels 66 68, curves within a vertical plane which extends parallel to the corresponding side wall 28 of the building. Both of the upper and lower sheets 72 and 74 of each roof panel are formed downwardly along the outer edges of the sheets to form integral depending flanges 86 (FIG. 9). An arcuate or uniformly curved gutter 88 extends 5. along the outer edges of each set of roof panels 66-68 and is secured to the corresponding downwardly projecting flanges 86 by a series of bolts 89. Each of the gutters 88 is preferably molded of fiberglass or vacuum formed of thermoplastic sheet material, and the adjacent ends of the gutters 88 are connected to each other at the outer end of the corresponding corner beam 55 and are also connected to a corresponding downspout A modified form of the joint construction between adjacent roof panels is shown in FIG. 13. In this embodiment, each of the roof panels 66' includes an upper skin or sheet 72', and each upper sheet has outwardly projecting side flanges 76 which are generally flat insteadof channel-shaped as shown in FIG. 4. The overlapping flanges 76'- of the adjacent roof panels are secured to the upper flat surface of a corresponding curved beam 55" by a series of radially spaced screws 106. The screws 106 extend through corresponding holes within a rigid tubular reinforcing member 108 and through resilient sealing washers 109 into the beam 55'. A flat strip 110 of resilient gasket material is sandwiched between the overlapping flanges 76 to form a water-tight seal. The reinforcing member 108assures that the screws 106 produce a uniform clamping pressure along the entire length of the overlapping flanges 76'.

Referring to FIG. 14, a plurality of the building structures or units described above may be joined together as illustrated by the plan view of three building units in FIG. 14. When the units are connected in this manner, the overhanging portions of the beams 55 and the roof panels 66-68 are removed along the adjacent side walls of the building units, and the corresponding side wall panels 28 are removed. This arrangement illustrates how the building structures of the invention may be .used to define adjoining rooms.

From the drawings and the above description, it is apparent that a building structure constructed in accordance with the present invention provides desirable features and advantages. One important feature is provided by the construction of the roof system with the use of the inner frame 45, the outer frame 25, the radially extending curved beams 55 and the part-spherical roof panels 66-68. These components provide for a roof system which can be conveniently and quickly erected and which has substantial strength for supporting heavy snow loads without deforming or buckling.

The outer coplanar curved edges of each set of roof panels 66-68 provide not only an attractive appearance but also provide for natural water drainage from the roof into the downspouts 90. The inner rigid frame 45 also provides for a skylight opening so that the inner portion of the building structure receives natural lighting. While a set of three roof panels 66-68 is used for Another feature is provided by the arrangement of the bridge-like wall panels 18 and the supporting corner posts 16 to form the outer hexagonal frame 25. The assembly of these components provides for first erecting the roof system and then subsequently inserting the preassembled rectangular wall panels 28. As a result,v

the building structure can be quickly erected. It is to be understood, however, that each segment-shaped wall panel 18 and the corresponding rectangular wall panel 28 may be constructed as one wall panel.

While the building structures herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise formsofstructure, and that changes may be made therein without departing from the scope and spirit of the invention. Y

The invention having thus been described, the following is claimed:

l. An improved building structure comprising a horizontal floor, a plurality of vertical planar wall members arranged to define a hexagon and projecting upwardly from said floor, means for rigidly connecting saidwall members to form a hexagonal outer frame, a hexagonal inner frame positioned concentrically within said outer frame and defining a center opening, a set of angularly arranged curved beams for each side of said outer frame and projecting generally radially outwardly from said inner frame over said outer frame with cantilevered outer end portions projecting outwardly from said outer frame, a set of complementary trapezoidal insulated roof panels mounted on said beams for each side of said outer frame and extending from said inner frame outwardly over said outer framein adjacent relation, each said roof panel having a substantially spherical curvature conforming substantially to the curvature of said beams, the radius of curvature of said beams and said roof panels being greater than the distance between opposite wall members of said outer-frame, each set of roof panels having outer edge surfaces curving uniformly within a vertical plane extending substantially parallel to the correspondingside of said outer frame, means for connecting adjacent edges of said roof panels to the corresponding said beams,.means forming a liquid-tight seal between adjacentedges of said roof panels, and means forming a transparent skylight cover for said center opening.

2. A building structure as defined in claim 1 wherein said outer and inner frames have corresponding parallel sides, and one set of said beams extends from each side of said inner frame over the corresponding side of said outer frame.

3. An improved building structure comprising a horizontal floor, a plurality of vertical planar wall members arranged to define a polygon and projecting upwardly from said floor, means for rigidly connecting said wall members to form a polygonalIy-shaped outer frame, an annular inner frame positioned concentrically within said outer frame and defining a center opening, a set of angularly arranged curved beams for each side of said outer frame and projecting generally radially outwardly from said inner frame over said outer frame with cantilevered outer end portions projecting outwardly from said outer frame, a set of complementary trapezoidal insulated roof panels mounted on said beams for each side of said outer frame and extending from said inner frame outwardly over said outer frame in adjacent relation, each said roof panel having a substantially spherical curvature conforming substantially to the curvature of said beams, each set of roof panels having outer edge surfaces curving uniformly within a vertical plane ex tending substantially parallel to the corresponding side of said outer frame, each of said roof panels being substantially trapezoid in configuration and includes an upper sheet and a lower sheet of plastics material, a core of insulation material between said upper and lower sheets, said upper sheet of 'each panel projects outwardly from the sides of the corresponding said core to form projecting flanges, said flanges of adjacent said panels are arranged in overlapping relation over the adjacent said beam, means for connecting adjacent edges of said roof panels to the corresponding adjacent said beams, and means forming a liquid-tight seal between adjacent edges of said roof panels.

4. A building structure as defined in claim 3 including a curved gutter member extending adjacent said outer edge surfaces of each set of said roof panels for collecting waterdraining from said roof panels.

5. A building structure as defined in claim3 wherein a set of three of said roofpanelsextend across each side of said outer frame. 1

6. A roof structure as defined in claim 3 wherein the radius of curvature of said beams and said roof panels 7 8. A building structure as defined in claim 3 wherein the upper sheet of each said roof panel includes an integral lip projecting downwardly from the outer .end of each said panel. 

1. An improved building structure comprising a horizontal floor, a plurality of vertical planar wall members arranged to define a hexagon and projecting upwardly from said floor, means for rigidly connecting said wall members to form a hexagonal outer frame, a hexagonal inner frame positioned concentrically within said outer frame and defining a center opening, a set of angularly arranged curved beams for each side of said outer frame and projecting generally radially outwardly from said inner frame over said outer frame with cantilevered outer eNd portions projecting outwardly from said outer frame, a set of complementary trapezoidal insulated roof panels mounted on said beams for each side of said outer frame and extending from said inner frame outwardly over said outer frame in adjacent relation, each said roof panel having a substantially spherical curvature conforming substantially to the curvature of said beams, the radius of curvature of said beams and said roof panels being greater than the distance between opposite wall members of said outer-frame, each set of roof panels having outer edge surfaces curving uniformly within a vertical plane extending substantially parallel to the corresponding side of said outer frame, means for connecting adjacent edges of said roof panels to the corresponding said beams, means forming a liquid-tight seal between adjacent edges of said roof panels, and means forming a transparent skylight cover for said center opening.
 2. A building structure as defined in claim 1 wherein said outer and inner frames have corresponding parallel sides, and one set of said beams extends from each side of said inner frame over the corresponding side of said outer frame.
 3. An improved building structure comprising a horizontal floor, a plurality of vertical planar wall members arranged to define a polygon and projecting upwardly from said floor, means for rigidly connecting said wall members to form a polygonally-shaped outer frame, an annular inner frame positioned concentrically within said outer frame and defining a center opening, a set of angularly arranged curved beams for each side of said outer frame and projecting generally radially outwardly from said inner frame over said outer frame with cantilevered outer end portions projecting outwardly from said outer frame, a set of complementary trapezoidal insulated roof panels mounted on said beams for each side of said outer frame and extending from said inner frame outwardly over said outer frame in adjacent relation, each said roof panel having a substantially spherical curvature conforming substantially to the curvature of said beams, each set of roof panels having outer edge surfaces curving uniformly within a vertical plane extending substantially parallel to the corresponding side of said outer frame, each of said roof panels being substantially trapezoid in configuration and includes an upper sheet and a lower sheet of plastics material, a core of insulation material between said upper and lower sheets, said upper sheet of each panel projects outwardly from the sides of the corresponding said core to form projecting flanges, said flanges of adjacent said panels are arranged in overlapping relation over the adjacent said beam, means for connecting adjacent edges of said roof panels to the corresponding adjacent said beams, and means forming a liquid-tight seal between adjacent edges of said roof panels.
 4. A building structure as defined in claim 3 including a curved gutter member extending adjacent said outer edge surfaces of each set of said roof panels for collecting water draining from said roof panels.
 5. A building structure as defined in claim 3 wherein a set of three of said roof panels extend across each side of said outer frame.
 6. A roof structure as defined in claim 3 wherein the radius of curvature of said beams and said roof panels is greater than the distance across said outer frame.
 7. A building structure as defined in claim 3 including polygonally-shaped transparent panel means for covering said center opening and forming a skylight therefor.
 8. A building structure as defined in claim 3 wherein the upper sheet of each said roof panel includes an integral lip projecting downwardly from the outer end of each said panel. 